Method for producing seamless shoe upper

ABSTRACT

A method for producing a seamless shoe upper includes the following steps of: providing a covering piece, a lining piece, and first and second screen-printing jigs having first and second screen portions respectively; surface treating the covering piece using a first treating agent through the first screen portion and the lining piece using a second treating agent through the second screen portion; distributing an adhesive onto the covering piece and the lining piece respectively through the first and second screen portions, so as to form first and second adhesive layers thereon; and bonding the covering piece with the lining piece by overlapping and pressing the first and second adhesive layers together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of Taiwanese Patent Application No. 102135345, filed on Sep. 30, 2013.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a method for forming a shoe, more particularly to a method for forming a seamless shoe upper.

2. Description of the Related Art

A shoe upper is often attached with various decorative pieces in order to create visual effects, to enhance aesthetic appeal, and/or to enhance recognition of trademarks. Conventionally, the decorative pieces are sewn on the shoe upper by human labor, which results in a relatively high production cost. In addition, threads that bond the decorative pieces with the shoe upper may be broken easily and cause the decorative pieces to be disengaged from the shoe upper.

To prevent the aforesaid problems, Taiwanese Utility Model No. M452973 discloses a method for forming a shoe upper by weaving desired patterns thereon. However, such weaving method can merely produce visual effects in a two-dimensional manner and would not lower the labor cost.

Taiwanese Utility Model No. 051274 and No. 073445 both disclose a method for forming a seamless shoe upper by utilizing foaming materials to create three-dimensional patterns. However, the method requires molds to define the three-dimensional patterns and thereby increases the production cost.

Taiwanese Patent No. 1322758 discloses another method that involves placing a lining layer and a base fabric into a molding cavity, followed by injection molding a plastic material on the base fabric to form a decorative piece. However, such method is limited for application to plastic materials only. That is, other materials, such as leather, cannot be used as an injection molding material for making the decorative piece.

Further, there is yet another conventional method for forming a seamless shoe upper including the following steps of distributing a hot-melt adhesive layer on a sheet, and attaching a release film and cutting the sheet to form a decorative piece with the desired shape. The decorative piece can thereafter be attached to a shoe upper via the hot-melt adhesive layer. However, such method wastes lots of hot-melt adhesives, and the bonding between the decorative piece and the shoe upper may not be strong enough since merely one hot-melt adhesive layer is used to bond the decorative piece with the shoe upper.

Taiwanese Patent Application Publication No. 200500023 discloses yet another method for producing a seamless shoe upper by coating a patterned adhesive layer on a shoe upper, followed by adhering powders onto the patterned adhesive layer utilizing a generated electrostatic field, so as to form decorative patterns on the shoe upper. However, such method requires expensive manufacturing equipments, such as electrostatic-field generating equipment, and thereby boosts up the production cost. In addition, the formed decorative patterns are often in a two-dimensional manner.

SUMMARY OF THE INVENTION

Therefore, the object of the present invention is to provide a method that may alleviate at least one of the aforementioned drawbacks of the prior art.

Accordingly, a method of the present invention for producing a seamless shoe upper includes the following steps of:

-   -   (a) providing a covering piece, a lining piece, a first         screen-printing jig having a first screen portion that         corresponds in shape to a bottom surface of the covering piece,         and a second screen-printing jig having a second screen portion;     -   (b) surface-treating the bottom surface of the covering piece         using a first treating agent through the first screen portion         and a top surface of the lining piece using a second treating         agent through the second screen portion;     -   (c) drying the covering piece and the lining piece so as to         remove the first and second treating agents on the bottom         surface of the covering piece and the top surface of the lining         piece, respectively;     -   (d) distributing an adhesive onto the bottom surface of the         covering piece and the top surface of the lining piece         respectively through the first and second screen portions, so as         to form first and second adhesive layers respectively on the         bottom surface of the covering piece and the top surface of the         lining piece;     -   (e) drying the first and second adhesive layers; and     -   (f) bonding the bottom surface of the covering piece with the         top surface of the lining piece by overlapping and pressing the         first and second adhesive layers together.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiment with reference to the accompanying drawings, of which:

FIG. 1 is a perspective view of a preferred embodiment of a method for producing a seamless shoe upper according to the invention, illustrating a step of providing a covering piece, a lining piece, first and second screen-printing jigs, and first and second substrates;

FIG. 2 is a fragmentary sectional view of the preferred embodiment, illustrating a step of surface-treating the covering piece and the lining piece;

FIG. 3 is a schematic sectional view of the preferred embodiment, illustrating a step of drying the covering piece and the lining piece;

FIG. 4 is a fragmentary sectional view of the preferred embodiment, illustrating a step of distributing an adhesive onto the covering piece and the lining piece;

FIG. 5 is a schematic sectional view of the preferred embodiment, illustrating a step of drying the adhesive to form first and second adhesive layers respectively on the covering piece and the lining piece;

FIG. 6 is a fragmentary sectional view of the preferred embodiment, illustrating a step of overlapping the first adhesive layer onto the second adhesive layer;

FIG. 7 is a fragmentary sectional view of the preferred embodiment, illustrating a step of bonding the first adhesive layer with the second adhesive layer by pressing;

FIG. 8 is a top view of the seamless shoe upper made by the method of the present invention; and

FIG. 9 is a fragmentary sectional view of the seamless shoe upper taken along line IX-IX of FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before the present invention is described in greater detail, it should be noted that like elements are denoted by the same reference numerals throughout the disclosure.

Referring to FIGS. 1 to 9, the preferred embodiment of a method for producing a seamless shoe upper according to the present invention includes the following steps of:

Step 1: providing a covering piece 1, a lining piece 2, first and second screen-printing jigs 100, 200, and first and second substrates 300, 400 (see FIG. 1).

The covering piece 1 has opposite top and bottom surfaces 102, 101, is previously cut into a predetermined shape, and can be made of plastic, artificial leather, natural leather or combinations thereof.

The lining piece 2 has opposite top and bottom surfaces 201, 202, and the shape of the lining piece 2 corresponds to the shape of the seamless shoe upper. The lining piece 2 can be made of textile, plastic, artificial leather, natural leather, or combinations thereof.

The first screen-printing jig 100 has a first main board 110 formed with a first meshed screen portion 120 that corresponds in shape to the bottom surface 101 of the covering piece 1. In this embodiment, the first screen-printing jig 100 further has a plurality of engaging segments 130 that are disposed at corners of the first main board 110 and that are configured in a pin shape.

The second screen-printing jig 200 has a second main board 210 formed with a second meshed screen portion 220. In this embodiment, the second screen-printing jig 200 further has a plurality of engaging segments 230 that are disposed at corners of the second main board 210 and that are configured in a pin shape. In this embodiment, the second screen portion 220 has a shape corresponding in shape to the first screen portion 120 (i.e., the second screen portion 220 is mirror-symmetrical in shape to the first screen portion 120).

As shown in FIG. 1 and further depicted in FIG. 2, the first substrate 300 has a plurality of first positioning portions 340 and a first top surface 322 formed with a first positioning groove 323 that corresponds in shape to the bottom surface 101 of the covering piece 1. In this embodiment, the engaging segments 130 of the first screen-printing jig 100 are configured as through holes and are operable to engage respectively the first positioning portions 340 of the first substrate 300. In this embodiment, the first substrate 300 includes a first outer plate 310, and a first inner plate 320 that is disposed on a top surface 311 of the first outer plate 310 and that has a top surface serving as the first top surface 322 of the first substrate 300. The first inner plate 320 is formed with a through hole that cooperates with the first outer plate 310 to define the first positioning groove 323. In this embodiment, a first releasable adhesive layer 330 is disposed on the top surface 311 of the first outer plate 310 and in the first positioning groove 323.

The second substrate 400 has a plurality of second positioning portions 440 that correspond in position to the first positioning portions 340 of the first substrate 300, and a second top surface 422 formed with a second positioning groove 423 that corresponds in shape to the bottom surface 202 of the lining piece 2. In this embodiment, the second positioning portions 440 are configured as through holes and are operable to engage respectively the engaging segments 230 of the second screen-printing jig 200. In this embodiment, the second substrate 400 includes a second outer plate 410, and a second inner plate 420 that is disposed on a top surface 411 of the second outer plate 410 and that has a top surface serving as the second top surface 422 of the second substrate 400. The second inner plate 420 is formed with a through hole that cooperates with the second outer plate 410 to define the second positioning groove 423. In this embodiment, a second releasable adhesive layer 430 is disposed on a top surface 411 of the second outer plate 410 and in the second positioning groove 423.

Step 2: placing the covering piece 1 into the first positioning groove 323 of the first substrate 300 (see FIG. 2) to removably retain the covering piece 1 therein by the first releasable adhesive layer 330, and placing the lining piece 2 into the second positioning groove 423 of the second substrate 400 to removably retain the lining piece 2 therein by the second releasable adhesive layer 430. It is worth noting that, the bottom surface 101 of the covering piece 1 faces upwardly while being retained in the first positioning groove 323, and the top surface 201 of the lining piece 2 faces upwardly while being retained in the second positioning groove 423.

Step 3: positioning the first screen-printing jig 100 with the first substrate 300 through the engagement between the engaging segments 130 of the first screen-printing jig 1 and the first positioning portions 340, such that the bottom surface 101 of the covering piece 1 is covered by the first screen portion 120 of the first screen-printing jig 100. Similarly, the second screen-printing jig 200 is positioned with the second substrate 400 through the engagement between the engaging segments 230 of the second screen-printing jig 2 and the second positioning portion 440, such that the top surface 201 of the lining piece 2 is covered by the second screen portion 220 of the second screen-printing jig 2. Thereafter, surface-treating the bottom surface 101 of the covering piece 1 is performed using a first treating agent through the first screen portion 120 of the first screen-printing jig 1. Surface-treating the top surface 201 of the lining piece 2 is also performed using a second treating agent through the second screen portion 220 of the second screen-printing jig 2. The first treating agent is capable of removing impurities attached on the bottom surface 101 of the covering piece 1, and is chosen depending on the surface property of the covering piece 1. This also applies for the second treating agent. In this embodiment, examples of the first or second treating agent can be, but are not limited to, WB Primer 6001LE, 6001E and 6006EAB, which are commercially available from GREAT EASTERN RESINS Co. Ltd.

Step 4: drying the covering piece 1 and the lining piece 2 to remove the first and second treating agents on the bottom surface 101 of the covering piece 1 and the top surface 201 of the lining piece 2, respectively (see FIG. 3) . During this step of this embodiment, the first and second substrates 300, 400 are disengaged from the first and second screen-printing jigs 100, 200, respectively, to allow efficient evaporation of the first and second treating agents.

Step 5: re-positioning the first and second screen-printing jigs 100, 200 with the first and second substrates 300, 400, respectively, and distributing an adhesive onto the bottom surface 101 of the covering piece 1 and the top surface 201 of the lining piece 2 respectively through the first and second screen portions 120, 220, so as to form first and second adhesive layers 10, 20 respectively on the bottom surface 101 of the covering piece 1 and the top surface 201 of the lining piece 2 (see FIG. 4). In this embodiment, the adhesive is distributed by spraying or using a roller. It should be noted that the second adhesive layer 20 is formed on a predetermined zone of the top surface 201, which corresponds in position to the second screen portion 220 of the second screen-printing jig 200.

Step 6: drying the first and second adhesive layers 10, 20 (see FIG. 5). In this embodiment, the first and second screen-printing jigs 100, 200 are disengaged from the first and second substrates 300, 400 again to allow efficient evaporation of organic solvents in the adhesive.

Step 7: overlapping the first and second adhesive layers 10, 20 (see FIG. 6). In this embodiment, a pressing apparatus 500 is utilized for positioning the first and second substrates 300, 400. As shown in FIG. 6, the pressing apparatus 500 includes a top mold 520 and a bottom mold 510 disposed below the top mold 520. One of the top and the bottom molds 510, 520 is formed with a plurality of pin-like segments 511 that correspond in position to the first and second positioning portions 340, 440 respectively of the first and second substrates 300, 400. In this embodiment, the bottom mold 510 is formed with the pin-like segments 511. The second substrate 400 is positioned on the bottom mold 510 with the second top surface 422 facing upward. To be specific, each of the pin-like segments 511 engages a respective one of the second positioning portions 440, so as to position the second substrate 400 on the bottom mold 510. Thereafter, the first substrate 300 is then positioned on the second substrate 400 with the first top surface 322 facing downwardly toward the second substrate 400. Similarly, each of the pin-like segments 511 engages a respective one of the first positioning portions 340 so as to position the first substrate 300 with the second substrate 400, thereby allowing the first adhesive layer 10 to overlap and to be registered with the second adhesive layer 20.

Step 8: bonding the bottom surface 101 of the covering piece 1 with the top surface 201 of the lining piece 2 by pressing the first and second adhesive layers 10, 20 (see FIG. 7). In this embodiment, the first and second substrates 300, 400 are pressed using the top and bottom molds 510, 520 of the pressing apparatus 500, so as to generate strong adhesion between the first and second adhesive layers 10, 20 and to fixedly bond the lining piece 2 with the covering piece 1 (see FIGS. 8 and 9).

It should be noted that, although only one covering piece 1 is exemplified in this embodiment, the method of the present invention is capable of bonding a plurality of the covering pieces 1 onto the lining piece 2, depending upon various designs of the seamless shoe upper. In this regard, the number of the first screen portions 110 of the first screen-printing jig 100 and the number of the second screen portions 210 of the second screen-printing jig 200 both correspond to the number of the covering pieces 1. In addition, positions of the first or second screen portions 120, 220 correspond to predetermined bonding positions of the lining piece 2, on which the covering pieces 1 bind respectively.

Another preferred embodiment of the method for producing the seamless shoe upper according to the present invention is similar to that of the first preferred embodiment. The difference therebetween resides in that the lining piece 2 has a shape which is larger than the seamless shoe upper. That is, in this embodiment, the method further includes a step of cutting the lining piece 2 into the shape of the seamless shoe upper after Step 8 (not shown in the Figures).

From the description above, the method according to the present invention has the following advantages:

-   -   (1) The covering piece 1 is fixedly bonded to the lining piece 2         via the strong adhesion between the first and second adhesive         layers 10, 20, so that the labor cost for sewing process in         making shoe uppers can be reduced.     -   (2) By utilizing the first and second adhesive layers 10, 20 to         bond the covering piece 1 with the lining piece 2, the material         to be used in making the covering piece 1 and the lining piece 2         is not limited. That is, the covering piece 1 can be made of         plastic, artificial leather, natural leather, or combinations         thereof.     -   (3) Since the first and second adhesive layers 10, 20 are formed         through the first and second screen portions 120, 220 that         correspond in shape to the bottom surface 101 of the covering         piece 1, excess amount of the adhesive is not needed.     -   (4) The first and second screen-printing jigs 100, 200 have         relatively simple structures, so that the production cost can be         correspondingly reduced.

While the present invention has been described in connection with what are considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements. 

What is claimed is:
 1. A method for producing a seamless shoe upper, comprising the following steps of: (a) providing a covering piece, a lining piece, a first screen-printing jig having a first screen portion that corresponds in shape to a bottom surface of the covering piece, and a second screen-printing jig having a second screen portion; (b) surface treating the bottom surface of the covering piece using a first treating agent through the first screen portion, and a top surface of the lining piece using a second treating agent via the second screen portion; (c) drying the covering piece and the lining piece so as to remove the first and second treating agents on the bottom surface of the covering piece and the top surface of the lining piece, respectively; (d) distributing an adhesive onto the bottom surface of the covering piece and the top surface of the lining piece respectively through the first and second screen portions, so as to form first and second adhesive layers respectively on the bottom surface of the covering piece and the top surface of the lining piece; (e) drying the first and second adhesive layers; and (f) bonding the bottom surface of the covering piece with the top surface of the lining piece by overlapping and pressing the first and second adhesive layers together.
 2. The method of claim 1, wherein, in step (a), the second screen portion of the second screen-printing jig corresponds in shape to the first screen portion of the first screen-printing jig.
 3. The method of claim 2, wherein, in step (a), the second screen portion of the second screen-printing jig is mirror-symmetric in shape to the first screen portion of the first screen-printing jig.
 4. The method of claim 1, wherein, in step (a), the covering piece is made of plastic, artificial leather, natural leather or combinations thereof.
 5. The method of claim 4, wherein, in step (a), the lining piece is made of textile, plastic, artificial leather, natural leather, or combinations thereof.
 6. The method of claim 1, further comprising: in step (a), providing a first substrate and a second substrate, the first substrate having a plurality of first positioning portions and a first top surface formed with a first positioning groove that corresponds in shape to the bottom surface of the covering piece, the second substrate having a plurality of second positioning portions corresponding respectively in position to the first positioning portions and a second top surface formed with a second positioning groove that corresponds in shape to the lining piece, disposing a first releasable adhesive layer in the first positioning groove, and disposing a second releasable adhesive layer in the second positioning groove; and prior to step (b), a step (b1) of placing the covering piece into the first positioning groove of the first substrate to removably retain the covering piece therein by the first releasable adhesive layer, and placing the lining piece into the second positioning groove of the second substrate to removably retain the lining piece therein by the second releasable adhesive layer.
 7. The method of claim 6, wherein: in step (a), the first screen-printing jig further has a plurality of engaging segments that are operable to engage respectively the first positioning portions of the first substrate, the second screen-printing jig further has a plurality of engaging segments that are operable to engage respectively the second positioning portions of the second substrate; and in step (b) and step (d), the first screen-printing jig is positioned with the first substrate through the engagement between the engaging segments of the first screen-printing jig and the first positioning portions of the first substrate, the second screen-printing jig being positioned with the second substrate through the engagement between the engaging segments of the second screen-printing jig and the second positioning portions of the second substrate.
 8. The method of claim 7, wherein, in step (a): the first substrate includes a first outer plate, and a first inner plate that is disposed on a top surface of the first outer plate and that has a top surface serving as the first top surface of the first substrate, and a through hole serving as at least a portion of the first positioning groove, the first releasable adhesive layer being disposed in the through hole of the first inner plate and on the top surface of the outer plate; and the second substrate includes a second outer plate, and a second inner plate that is disposed on a top surface of the second outer plate and that has a top surface serving as the second top surface of the second substrate, and a through hole serving as at least a portion of the second positioning groove, the second releasable adhesive layer being disposed in the through hole of the second inner plate and on the top surface of the second outer plate.
 9. The method of claim 7, wherein: in step (a), the first and second positioning portions respectively of the first and second substrates are through holes, and the first and second engaging segments respectively of the first and second screen-printing jigs are configured in a pin shape; and step (f) is performed using a pressing apparatus including a bottom mold and a top mold, one of the bottom and top molds being formed with a plurality of pin-like segments each of which engages a respective one of the first positioning portions of the first substrate, and a respective one of the second positioning portions of the second substrate. 